RFID tag that provides a flat print area and a pinch roller that enables the same

ABSTRACT

A radio-frequency identification (RFID) tag includes a face stock and an RFID device. The face stock has a printable side and an inlay side, with the RFID device mounted to the inlay side. A layer of adhesive is coated on the inlay side of the face stock. A liner is releasably adhered to the layer of adhesive and includes a relief area that accommodates for defection of the RFID device. The accommodation of the thickness of the RFID device results in a tag that has a substantially uniform printable surface. Accordingly, when passing through a printer, the printable surface is maintained substantially flat or linear at the print head of the printer, thereby minimizing jamming and enhancing printability. A pinch roller for a printer also accommodates for deflection of the RFID tag by providing a deformable section along a length thereof the body that has a greater resiliency than the rest of the body. At the location of the RFID device, the layer of adhesive may also include a blank that is substantially free of adhesive for accommodating the RFID device.

FIELD OF THE INVENTION

The present invention relates to radio-frequency identification (RFID) tags. The invention also relates to RFID tags with enhanced printing capabilities.

BACKGROUND OF THE INVENTION

Conventional RFID tags have a substrate or face stock on one side of which an RFID device, chip, or strap is mounted. An adhesive layer is coated over the RFID device, and a release liner is applied to the adhesive layer. Accordingly, there is an uneven thickness in the RFID tag at the location of the RFID device, chip, or strap, such that the RFID tag bulges at this location.

It is common to print information on the RFID tag after the tag has been manufactured, either by the manufacturer or by the end user. However, because of the uneven thickness, when passing through a printer during a printing process, the RFID tag has a tendency to jam in the printer or to otherwise present an undesirable printing surface for the print head of the printer, thereby resulting in print distortion and less than optimal printing. In addition, compressing the RFID tag between the pinch roller and the print head may damage the RFID device and associated inlayed structure or may damage the print head itself, thereby decreasing the life of the print head.

In view of the foregoing, there is a need in the art for RFID tags that mitigate or eliminate the problems associated with printing on conventional tags. The present invention satisfies this need.

BRIEF SUMMARY OF THE INVENTION

In accordance with exemplary embodiments of the present invention, radio-frequency identification (RFID) tags enable efficient, reliable printing by providing tags that are effectively flat along their transverse axis as they pass below the print head during the printing process.

According to one aspect of the invention, an RFID tag includes a face stock and an RFID device. The face stock has a printable side and an inlay side, with the RFID device mounted to the inlay side. A layer of adhesive is coated on the inlay side of the face stock. A liner is releasably adhered to the layer of adhesive and includes a relief area that is coincident with or located at the RFID device. The relief area may include a plurality of weakening lines, such as scored or die cut lines in the liner, that enable the liner to flex or separate when the RFID tag is compressed to accommodate any deflection of the RFID device. In other embodiments, the relief area includes a seat for accommodating the RFID device.

According to another aspect, the layer of adhesive includes a blank that is substantially free of adhesive at the location of the RFID device. The blank essentially provides a recess that effectively accommodates the thickness of the RFID device, thereby resulting in a tag that has a substantially uniform thickness. Accordingly, when passing through a printer, the printable surface is maintained substantially flat or linear at the print head of the printer, thereby minimizing jamming and enhancing printability.

According to still another aspect, a pinch roller for a printer also accommodates any unevenness in the print surface of the RFID tag when passing through a printer. The pinch roller includes a body that is rotatable about a transverse axis and a deformable section disposed along a length of the body. The deformable section deforms to a greater degree than the rest of the body in a normal direction that is orthogonal to the transverse axis. Accordingly, when an RFID tag with an uneven thickness passes through the printer, the deformable section of the pinch roller accommodates the uneveness by compressing or deflecting in the normal direction.

Other features and advantages of the present invention will become apparent to those skilled in the art from a consideration of the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a plan view of an exemplary embodiment of an RFID tag that compensates for a thickness of an RFID device;

FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1;

FIG. 3 is a plan view of a layer of adhesive of an RFID tag;

FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 3;

FIG. 5 illustrates a printing process utilizing an RFID tag with a substantially uniform thickness;

FIG. 6 is a cross-sectional view illustrating some of the embodiments of a layer of adhesive;

FIG. 7 is a cross-sectional view illustrating other embodiments of a layer of adhesive;

FIGS, 8, 9, 10, and 11 are plan views respectively illustrating alternative embodiments of a liner with a deformable section;

FIG. 12 is a cross-sectional view taken along line 12-12 of FIG. 8;

FIG. 13 is a cross-sectional view illustrating a relief area of a liner flexing under deflection from an RFID device;

FIG. 13A is a cross-sectional view illustrating a liner with a seat for accommodating an RFID device;

FIG. 13B is a cross-sectional view illustrating a liner with an opening for accommodating an RFID device;

FIG. 14 is a perspective view of pinch roller for a printer;

FIG. 15 is a cross-sectional view of the pinch roller;

FIG. 16 illustrates a printing process utilizing a pinch roller with a deformable section and an RFID tag with substantially uniform thickness; and

FIG. 17 illustrates a printing process utilizing a pinch roller with a deformable section and an RFID tag that has a greater thickness at the location of an RFID device.

DETAILED DESCRIPTION OF THE INVENTION

Referring more particularly to FIGS. 1 and 2 of the drawings, a radio-frequency identification (RFID) tag 100 includes a face stock 102 and an RFID device 104. The face stock 102 may be described as having a printable side or surface 106 and an inlay side or surface 108. The RFID device 104 is mounted to or disposed on the inlay side 108 of the face stock 102 and may include any type of RFID structure, including chips, straps, power source (for active devices), and connecting structure for coupling with an antenna 110, as known in the art.

The face stock 102 may include an inlay substrate 114, such as a layer of polyethylene terephthalate (PET), applied to the inlay side 108 on which the RFID device 104 (such as a microchip) and the antenna 110 may be disposed. In addition, a layer of adhesive 116, such as a pressure sensitive adhesive (PSA), may be coated on the inlay side 108 of the face stock 102, and a liner 118 may be releasably adhered to the layer of adhesive 116.

With additional reference to FIGS. 3 and 4, according to a number of embodiments, the layer of adhesive 116 may include a blank 120 formed or defined therein that is substantially free of adhesive, as particularly shown in FIG. 4. The blank 120 may be described as being spatially larger than and coincident with the RFID device 104 so that the RFID device 104 is received or located therewithin, as particularly shown in FIG. 2. Alternatively, the blank 120 may be described as being disposed on the inlay side 108 of the face stock 102 and defining an area that is substantially free of adhesive and in which the RFID device 104 is disposed.

Depending on the respective thicknesses of the RFID device and the adhesive, it may be seen that the blank 120 can compensate for the thickness of the RFID device 104, either partially or completely, as described below.

For the purposes of this description, the word blank indicated by reference numeral 120 is used to describe an area or region in the layer of adhesive 116 that is free of adhesive.

This spatial void in the layer of adhesive 116 may be alternatively described as, for example, a window, an opening, an aperture, or a seat in the adhesive 116.

Thus, in some of the embodiments, the tag 100 may be configured so that a thickness t is substantially uniform along a transverse axis T, as shown in FIG. 2. Accordingly, when the tag 100 is passing through a printer 122 with a print head 124 and a pinch roller 126, as shown in FIG. 5, the printable side 108 of the face stock 102 remains substantially linear, or flat, along the transverse axis T of the tag as it passes between the two. In other words, any deflection of or upset in the printable side 108 of the face stock 102 caused by the RFID device 104 is minimized or substantially eliminated, thereby maintaining a printing area of the tag 100 essentially flat to enhance printing.

In other embodiments, such as shown in FIG. 6, the layer of adhesive 116 may have a thickness t_(A) that is slightly greater than a thickness t_(D) of the RFID device 104 so that the device 104 is effectively sunken within the blank 120, leaving a small recess 128. The recess 128 may provide spatial or directional accommodation in a normal direction N when the tag 100 is compressed between a print head and a pinch roller in a printer due to differing resiliency between the adhesive 116 and the RFID device 104.

In still other embodiments, such as shown in FIG. 7, the layer of adhesive 116 may have a thickness t_(A) that is slightly less than a thickness t_(D) of the RFID device 104 so that the device 104 projects out of the blank 120 slightly. In such an embodiment, additional spatial accommodation in the normal direction N can be accomplished by providing a liner 118 with accommodating structure, as described below.

More specifically, in a number of embodiments, such as the alternative embodiments respectively shown in FIGS. 8, 9, 10, and 11, the liner 118 may include a relief area 130 centered about or coincident with the location of the RFID device 104 (not shown in these figures; see, e.g., FIG. 2), which location is indicated by L. In some of the embodiments, the relief area 130 may include one or more weakening lines 132. The weakening lines 132 may include surface scores (i.e., cuts into but not extending through the liner 118) or, alternatively, may include die cuts 134 that extend completely through the thickness of the liner as shown in FIG. 12. The weakening lines 132 accommodate deflection of the RFID device 104 in the normal direction by allowing or enabling the liner 118 to separate and flex in the normal direction N under compression, as shown in FIG. 13.

As examples of commercial embodiments, the thickness of the liner 118 may range from about 2 mil to about 8 mil, and the thickness of the RFID chip 104 may range from about 5 mil to about 10 mil. For example, if the device or chip 104 is about 5 ml, then the liner 118 may be selected to be about 8 mil.

In this regard, rather than providing a blank 120 in the adhesive layer 116, a recess or seat 135 may be formed in the liner 118 at the location of or coincident with the RFID device 104 as shown in FIG. 13A. In some of the embodiments, the seat 135 may be spatially larger than the RFID device 104 so that the device 104 is received within the seat as shown. These embodiments may be described in that the relief area 130 includes the seat 135. In these embodiments, the layer of adhesive 116 is relatively thin, with the thickness of the liner 118 being greater than the thickness of the device 104. Accordingly, the device 104 is accommodated by the seat 135 of the liner 118. Also in these embodiments, the relief area 130 may also include the weakening lines 132 in addition to the seat 135, if desired. In still other embodiments, the seat 135 may be in the form of a blank as described above in which the seat 135 is in the form of an opening through the liner 118, as shown in FIG. 13B.

For the purposes of this description, the term relief area is used to describe an area or structure of the tag 100 that enables distortion of the tag 100 when under stress or that allows the RFID device 104 to deflect under force, thereby entering the original or normal volume of the liner 118. The distortion or deflection may be either permanent or temporary.

In still other embodiments, accommodation of deflection of an RFID tag in the normal direction N may be accomplished by a pinch roller 126 as shown in FIGS. 14 and 15. The pinch roller 126 includes a body 134 that is rotatable about a transverse axis T. In a number of embodiments, the body 134 may include a deformable section 136 disposed along a length L thereof.

The deformable section 136 is configured to deform to a greater degree in response to a given force than the rest of the body 134. In other words, the deformable section 136 is deformable, deflectable, or compressible to a greater degree than the rest of the body 134 in the normal direction N that is orthogonal to the transverse axis T. In addition, the deformable section 136 may also be resilient in that the deformable section 136 is able to resume its original shape or position after being compressed or deformed. In a number of embodiments in which an elastic or resilient material is used, the deformable section 136 may be described as being “softer” than the rest of the body 134.

In some of the embodiments, the deformable section 136 may include foams such as closed-cell foams. In other embodiments, the deformable section 136 may be implemented with an electrically controllable material, such as an electro-active polymer with controllable parameters that can be softened at the deformable section 136 on command.

More specifically, as shown in FIG. 16, in a printing process in which the tag 100 has a uniform thickness in the normal direction N, and therefore, does not deflect in the normal direction N, the deformable section 136 does not defect in the normal direction N, and the printing side 108 is maintained substantially linear or flat along the transverse axis T for printing by the print head 124.

However, in a printing process in which the tag 110 does not have a uniform thickness and, therefore, deflects in the normal direction N when compressed between the print head 124 and the pinch roller 126, as shown in FIG. 17, the deformable section 136 correspondingly deflects in the normal direction N to accommodate the deflection of the RFID tag 100. Accordingly, a substantially linear or flat printing surface 108 is maintained along the transverse axis T for printing by the print head 124.

In other words, a normal separation S may be defined between the print head 124 and the pinch roller 126 in a normal, non-deflecting printing process. In a printing process in which an RFID tag 100 has a greater thickness at a location of an RFID device 104, thereby resulting in deflection, then the pinch roller 126 can accommodate this greater thickness at the location of the RFID device 104 by increasing the separation S between the print head 124 and the pinch roller 126 by a defection separation AS, thereby maintaining the printable side 108 of the face stock 102 substantially linear or flat along the transverse axis T. The deformation of the deformable section 136 is temporary in that after the tag 100 has passed through the printer, the deformable section 136 returns to a normal condition under the resiliency thereof.

Those skilled in the art will understand that the preceding embodiments of the present invention provide the foundation for numerous alternatives and modifications thereto. For example, rather than a single deformable section 136 along the body 134 of the roller 126, a plurality of such deformable sections may be provided. Alternatively, the entire length of the body 134 of the roller 126 may be made from a material that is substantially resilient to accommodate any local deflection of the printing stock or RFID tag 100. These other modifications are also within the scope of the present invention. Accordingly, the present invention is not limited to that precisely as shown and described in the present invention. 

1. A radio-frequency identification (RFID) tag comprising: a face stock with a printable side and an inlay side; an RFID device mounted to the inlay side of the face stock; a layer of adhesive coated on the inlay side of the face stock; and a liner releasably adhered to the layer of adhesive and including a relief area that is coincident with the RFID device.
 2. The tag of claim 1 wherein the relief area includes a weakening line.
 3. The tag of claim 1 wherein the relief area includes a plurality of the weakening lines.
 4. The tag of claim 3 wherein the plurality of weakening lines comprises die cut lines.
 5. The tag of claim 1 wherein the relief area includes a seat in which the RFID device is receivable.
 6. The tag of claim 1 wherein the seat in the form of an opening in the liner.
 7. The tag of claim 1 wherein the layer of adhesive includes a blank that is free of adhesive, spatially larger than the RFID device, and coincident with the RFID device such that the RFID device is located therewithin.
 8. A radio-frequency identification (RFID) tag comprising: a face stock with a printable side and an inlay side; an RFID device mounted to the inlay side of the face stock; and a layer of adhesive coated on the inlay side of the face stock and having a blank that is: free of adhesive; spatially larger than the RFID device; and coincident with the RFID device such that the RFID device is located therewithin.
 9. The tag of claim 8 further comprising a liner releasably adhered to the layer of adhesive.
 10. The tag of claim 9 wherein the liner includes a relief area coincident with the RFID device.
 11. The tag of claim 10 wherein the relief area includes a plurality of the weakening lines.
 12. The tag of claim 11 wherein the plurality of weakening lines comprise die cut lines.
 13. The tag of claim 10 wherein the relief area includes a seat in which the RFID device is receivable.
 14. The tag of claim 10 wherein the relief area includes an opening in which the RFID device is receivable.
 15. A method of printing on an RFID tag in a printer, the RFID tag including a face stock with a printable side and an inlay side and an RFID device disposed on the inlay side of the face stock such that the RFID tag has a greater thickness at the location of the RFID device than at other areas of the RFID tag, the printer including a print head and a pinch roller with a given separation therebetween, a transverse axis being defined along a length of the pinch roller and orthogonal to a print path of the printer, the method comprising: maintaining the printable side of the face stock substantially linear along the transverse axis while the RFID tag is passing through the printer.
 16. The method of claim 15 wherein the maintaining step further comprises maintaining the printing surface of the face stock substantially linear while the RFID tag is passing between the pinch roller and the print head.
 17. The method of claim 16 wherein the maintaining step further comprises maintaining the printing surface of the face stock substantially linear at the location of the RFID device.
 18. The method of claim 16 wherein the maintaining step further comprises increasing a separation between the print head and the pinch roller at an area where the RFID device passes therebetween while maintaining the given separation between the print head and the pinch roller at other areas.
 19. A printer comprising: a print head; and a pinch roller that is rotatable about a transverse axis; the pinch roller including a body with a deformable section; whereby the deformable section is deformable to a greater degree than the rest of the body in a normal direction that is orthogonal to the transverse axis.
 20. A pinch roller for a printer including a print head, the pinch roller comprising: a body that is rotatable about a transverse axis; and a deformable section disposed along a length of the body; the deformable section being deformable to a greater degree than the rest of the body in a normal direction that is orthogonal to the transverse axis. 